IMPROVEMENT OF HEAT AFFECTED ZONE OF GTAWed 5754 ALUMINUM ALLOY WITH FSP

Year 2023, Volume: 11 Issue: 3, 758 - 769, 01.09.2023

Fatih Kahraman , Gökçe Mehmet Gençer , Coşkun Yolcu

https://doi.org/10.36306/konjes.1255353

Abstract

In this study, post-weld friction stir processing (FSP) was applied to eliminate the grain coarsening disadvantages encountered in the heat-affected zone when joining AA5754 aluminum alloy with Gas Tungsten Arc Welding (GTAW). As a result of welding in two passes and with the low heat input by selecting the appropriate welding parameters, all welding seams were produced without macro defects. Despite all these precautions, grain coarsening has occurred in the Heat Affected Zone (HAZ), as expected. Significant amounts of grain refinement were detected as a result of the FSP applied to the regions with grain coarsening. Consequently, the grain refinement in the HAZ, the tensile strength increased slightly, in contrast with ductility has significantly increased (around from 6% to 19%). In the tensile tests, the rupture occurred in the HAZ in the GTAWed specimens, while the rupture occurred in the base material close to the HAZ in all FSPed specimens. In addition, the high hardness values of HAZ of the GTAWed samples were reduced to the base material hardness values in all FSPed samples, resulting in a more homogeneous hardness distribution.

Keywords

AA5754, Gas Tungsten Arc Welding, Friction Stir Processing, Mechanical Properties, Microstructure

References

• M. R. Islam, M. Ishak, L. H. Shah, S. R. A. Idris, C. Meriç, “Dissimilar welding of A7075-T651 and AZ31B alloys by gas metal arc plug welding method,” The International Journal of Advanced Manufacturing Technology, vol. 88, June, pp. 2773-2783, 2017.
• H. Okuyucu, A. Kurt, E. Arcaklioglu, “Artificial neural network application to the friction stir welding of aluminum plates,” Materials & Design, vol. 28, no. 1, Aug., pp. 78-84, 2007.
• P. Bamberg, G. Gintrowski, Z. Liang, A. Schiebahn, U. Reisgen, N. Precoma, C. Geffers, “Development of a new approach to resistance spot weld AW-7075 aluminum alloys for structural applications: an experimental study–Part 1,” Journal of Materials Research and Technology, vol. 15, Nov. Dec., pp. 5569-5581, 2021.
• N. Karunakaran, V. Balasubramanian, “Effect of pulsed current on temperature distribution, weld bead profiles and characteristics of gas tungsten arc welded aluminum alloy joints,” Transactions of Nonferrous Metals Society of China, vol. 21, no. 2, Feb., pp. 278-286, 2011.
• P. Praveen, P. K. D. V. Yarlagadda, “Meeting challenges in welding of aluminum alloys through pulse gas metal arc welding,” Journal of Materials Processing Technology, vol. 164-165, May, pp. 1106-1112, 2005.
• P. Kah, R. Rajan, J. Martikainen, R. Suoranta, “Investigation of weld defects in friction-stir welding and fusion welding of aluminium alloys,” International Journal of Mechanical and Materials Engineering, vol. 10, no. 1, Dec., pp. 1-10, 2015
• C. Zhao, Z. Luo, Y. Li, M. Feng, W. Xuan, “Inverse heat conduction model for the resistance spot welding of aluminum alloy,” Numerical Heat Transfer, Part A: Applications, vol. 70, no. 12, Nov., pp. 1330-1344, 2016.
• R. Xiao, X. Zhang, “Problems and issues in laser beam welding of aluminum–lithium alloys,” Journal of Manufacturing Processes, vol. 16, no. 2, April, pp. 166-175, 2014.
• R. Xiao, J. Yang, C. Tan, Z. Shen, Z. Yu, “Fabrication of high strength and lightweight dissimilar material joints by laser: a review,” Advanced Laser Processing and Manufacturing III, vol. 11183, Nov., pp. 32-37, 2019.
• A. Yazdipour, K. Dehghani, “Modeling the microstructural evolution and effect of cooling rate on the nanograins formed during the friction stir processing of Al5083,” Materials Science and Engineering: A, vol. 527, no. 1-2, Dec., pp. 192-197, 2009.
• A. K. Bodukuri, K. Eswaraiah, K. Rajendar, “Comparison of Aluminum Alloy 5083 properties on TIGW and FSW Processes,” Materials Today: Proceedings, vol. 4, no. 9, Oct., pp. 10197-10201, 2017.
• S. B. Aziz, M. W. Dewan, D. J. Huggett, M. A. Wahab, A. M. Okeil, T. Warren Liao, “Impact of Friction Stir Welding (FSW) process parameters on thermal modeling and heat generation of aluminum alloy joints,” Acta Metallurgica Sinica (English Letters), vol. 29, July, pp. 869-883, 2016.
• T. Hirata, T. Oguri, H. Hagino, T. Tanaka, S. W. Chung, Y. Takigawa, K. Higashi, “Influence of friction stir welding parameters on grain size and formability in 5083 aluminum alloy,” Materials Science and Engineering: A, vol. 456, no. 1-2, May, pp. 344-349, 2007.
• A. Ghiasvand, M. Kazemi, M. Mahdipour Jalilian, H. Ahmadi Rashid, “Effects of tool offset, pin offset, and alloys position on maximum temperature in dissimilar FSW of AA6061 and AA5086,” International Journal of Mechanical and Materials Engineering, vol. 15, May, pp. 1-14, 2020.
• P. Upadhyay, A. Reynolds, “Effect of backing plate thermal property on friction stir welding of 25-mm-thick AA6061,” Metallurgical and Materials Transactions A, vol. 45, Nov., pp. 2091-2100, 2014.
• C. T. Canaday, M. A. Moore, W. Tang, A. P. Reynolds, “Through thickness property variations in a thick plate AA7050 friction stir welded joint,” Materials Science and Engineering: A, vol. 559, Jan., pp. 678-682, 2013.
• A. K. Lakshminarayanan, V. Balasubramanian, K. Elangovan, “Effect of welding processes on tensile properties of AA6061 aluminium alloy joints,” The International Journal of Advanced Manufacturing Technology, vol. 40, Jan., pp. 286-296, 2009.
• K. Vasu, H. Chelladurai, A. Ramaswamy, S. Malarvizhi, V. Balasubramanian, “Effect of fusion welding processes on tensile properties of armor grade, high thickness, non-heat treatable aluminium alloy joints,” Defence Technology, vol. 15, no. 3, June, pp. 353-362, 2019.
• A. Kumar, S. Sundarrajan, “Optimization of pulsed TIG welding process parameters on mechanical properties of AA 5456 Aluminum alloy weldments,” Materials & Design, vol. 30, no. 4, April, pp. 1288-1297, 2009.
• L. Wang, M. Gao, C. Zhang, X. Zeng, “Effect of beam oscillating pattern on weld characterization of laser welding of AA6061-T6 aluminum alloy,” Materials & Design, vol. 108, Oct., pp. 707-717, 2016.
• Z. Tang, F. Vollertsen, “Influence of grain refinement on hot cracking in laser welding of aluminum,” Welding in the World, vol. 58, March, pp. 355-366, 2014.
• M. Sheikhi, F. M. Ghaini, H. Assadi, “Prediction of solidification cracking in pulsed laser welding of 2024 aluminum alloy,” Acta Materialia, vol. 82, Jan., pp. 491-502, 2015.
• M. Chludzinski, R. E. dos Santos, C. Churiaque, M. Ortega-Iguña, J. M. Sánchez-Amaya, “Pulsed laser welding applied to metallic materials—A material approach,” Metals, vol. 11, no. 4, April, pp. 640, 2021.
• H. Hekmatjou, H. Naffakh-Moosavy, “Hot cracking in pulsed Nd: YAG laser welding of AA5456,” Optics & Laser Technology, vol. 103, July, pp. 22-32, 2018.
• H. Ebrahimzadeh, H. Farhangi, S. A. A. A. Mousavi, “Hot cracking in autogenous welding of 6061-T6 aluminum alloy by rectangular pulsed Nd: YAG laser beam,” Welding in the World, vol. 64, April, pp. 1077-1088, 2020
• S. Mironov, Y. S. Sato, H. Kokawa, “Microstructural evolution during friction stir-processing of pure iron,” Acta Materialia, vol. 56, no. 11, June, pp. 2602-2614, 2008.
• C. Vidal, V. Infante, “Fatigue behavior of friction stir-welded joints repaired by grinding,” Journal of Materials Engineering and Performance, vol. 23, Jan., pp. 1340-1349, 2014.
• P. Schempp, C. Schwenk, M. Rethmeier, C. Edward, “Weld metal grain refinement of aluminium alloy 5083 through controlled additions of Ti and B,” Materials Testing, vol. 53, no. 10, May, pp. 604-609, 2011.
• N. Murali, M. Sokoluk, X. Li, “Study on aluminum alloy joints welded with nano-treated Al-Mg-Mn filler wire,” Materials Letters, vol. 283, Jan., pp. 128739, 2021.
• N. K. Babu, M. K. Talari, D. Pan, Z. Sun, J. Wei, K. Sivaprasad, “Microstructural characterization and grain refinement of AA6082 gas tungsten arc welds by scandium modified fillers,” Materials Chemistry and Physics, vol. 137, no. 2, Dec., pp. 543-551, 2012.
• V. Patel, W. Li, A. Vairis, V. Badheka, “Recent development in friction stir processing as a solid-state grain refinement technique: microstructural evolution and property enhancement,” Critical Reviews in Solid State and Materials Sciences, vol. 44, no. 5, July, pp. 378-426, 2019.
• J. Gandra, R. M. Miranda, P. Vilaça, “Effect of overlapping direction in multipass friction stir processing,” Materials Science and Engineering: A, vol. 528, no. 16–17, June, p. 5592-5599, 2011.
• M. Samiuddin, J. L. Li, M. Taimoor, M. N. Siddiqui, S. U. Siddiqui, J. T. Xiong, “Investigation on the process parameters of TIG-welded aluminum alloy through mechanical and microstructural characterization,” Defence Technology, vol. 17, no. 4, Aug., pp. 1234-1248, 2021.
• Y. Zhao, F. Chen, C. Cao, C. Chen, R. Xie, “Effect of CMT welding heat input on microstructure and properties of 2A14 aluminum alloy joint,”. Metals, vol. 12, no. 12, Dec., pp. 2100, 2022.
• G. Çam, G. İpekoğlu, “Recent developments in joining of aluminum alloys,” The International Journal of Advanced Manufacturing Technology, vol. 91, Dec., pp. 1851-1866, 2017.
• V. V. Bulatov, W. Cai, R. Baran, K. Kang, “Geometric aspects of the ideal shear resistance in simple crystal lattices,” Philosophical Magazine, vol. 86, no. 25-26, Nov., pp. 3847-3859, 2006.
• M. Grujicic, S. Ramaswami, J. S. Snipes, V. Avuthu, R. Galgalikar, Z. Zhang, “Prediction of the grain-microstructure evolution within a Friction Stir Welding (FSW) joint via the use of the Monte Carlo simulation method,” Journal of Materials Engineering and Performance, vol. 24, Aug., pp. 3471-3486, 2015.
• Y. Hu, Y. Niu, Y. Zhao, W. Yang, X. Ma, J. Li, “Friction stir welding of CoCrNi medium-entropy alloy: recrystallization behaviour and strengthening mechanism,” Materials Science and Engineering: A, vol. 848, July, pp. 143361, 2022.
• S. Kumar, A. S. Shahi, “Effect of heat input on the microstructure and mechanical properties of gas tungsten arc welded AISI 304 stainless steel joints,” Materials & Design, vol. 32, no. 6, June, pp. 3617-3623, 2011.
• P. C. Adamczuk, I. G. Machado, J. A. E. Mazzaferro, “Methodology for predicting the angular distortion in multi-pass butt-joint welding,” Journal of Materials Processing Technology, vol. 240, Feb., pp. 305-313, 2017.
• A. G. Rao, V. P. Deshmukh, N. Prabhu, B. P. Kashyap, “Ductilizing of a brittle as-cast hypereutectic Al–Si alloy by friction stir processing,” Materials Letters, vol. 159, Nov., pp. 417-419, 2015.
• S. Tutunchilar, M. B. Givi, M. Haghpanahi, P. Asadi, “Eutectic Al–Si piston alloy surface transformed to modified hypereutectic alloy via FSP,” Materials Science and Engineering: A, vol. 534, Feb., pp. 557-567, 2012.
• Y. Yang, P. Hua, X. Li, K. Chen, W. Zhou, “Effect of multipass on microstructure and impact toughness of as-cast Al–20Si alloy via friction stir processing,” Physics of Metals and Metallography, vol. 120, Dec., pp. 1126-1132, 2019.
• S. Malarvizhi, V. Balasubramanian, “Effect of welding processes on AA2219 aluminium alloy joint properties,” Transactions of Nonferrous Metals Society of China, vol. 21, no. 5, May, pp. 962-973, 2011.
• H. Mehdi, R. S. Mishra, “Study of the influence of friction stir processing on tungsten inert gas welding of different aluminum alloy,” SN Applied Sciences, vol. 1, June, pp. 1-11, 2019.